Fuel Tank System, Removing and Installing

Fuel tank components, removing and installing
1- Sealing cap
2- Seal
- Replace if damaged
3- 1 Nm (9 inch lbs.)
4- Tank flap unit
^ with rubber cup
5- 10 Nm (7 ft. lbs.)
6- Vent pipe
7- Change-over valve
^ Removing: unclip out of side support
- Before installing, remove sealing cap (item 1)
^ Checking
=> Refer to Fuel tank components, removing and installing Fig. 2.
8- O-ring
- Replace if damaged
9- EVAP canister
10- Wiring routing
^ in long member
11- Vent pipe
- Ensure it is securely seated
- Secure using spring clips
12- Fuel tank
- Support with VAG 1383 A engine/transmission jack when removing
^ Removing and installing:
13- Heat shield
^ for fuel tank
14- Clamping washer
15- Fuel tank cover
16- 25 Nm (18 ft. lbs.)
17- Mounting straps
- Note differing length
^ Installed position: Attaching points (holes) point in direction of travel
18- Fuel filter
^ Installed position: -arrow- points in direction of flow
19- Screw clip
20- Supply line
^ Black
^ to fuel rail
- Ensure it is securely seated
21- Vent line
^ White
^ Clipped onto top of fuel tank
^ with EVAP canister purge regulator valve N80
- Ensure it is securely seated
22- Sealing ring
- Replace if damaged
- Coat with fuel when installing
23- Fuel delivery unit
- Note installed position on fuel tank => Fig. 1
^ Removing and installing:
^ Fuel pump, checking:
=> Clean strainer if soiled
24- Union nut
- Remove and install using 3217 wrench
25- Supply line
^ Black
^ Clipped to side of fuel tank
- Ensure it is securely seated
26- Return line
^ Blue or blue markings
^ Clipped to side of fuel tank
- Ensure it is securely seated from fuel rail
27- Gravity/overflow valve
- Check valve for flow:
^ Valve vertical: OPEN, Valve tilted 45°: CLOSED
28- Pressure retention valve
^ for fuel reservoir ventilation
^ Checking:
=> Fig. 3
29- Ground connection
- Ensure it is securely seated





Fig. 1 Fuel delivery unit flange, installed position

Notes:
^ Mark on sensor must align with mark on fuel tank -arrows-.
^ Blue or blue marked return line -7- to connection with identification -R-.
^ Black supply line -2- to connection with identification -V-.
^ After installing fuel delivery unit flange, ensure that supply return and breather lines are still clipped to the fuel tank.





Fig. 2 Change-over valve, checking
^ Valve in rest position: CLOSED
^ Valve pushed in direction of arrow: OPEN





Fig. 3 Pressure retention valve, checking

Notes:
^ From the vent valve direction, the pressure retention valve is open in both directions of flow -arrow 1-.
^ From the junction piece for the EVAP canister purge regulator valve 1 direction, it is only open in one direction of flow -arrow -2-.